Anti-noise component

Abstract

A method for manufacturing an anti-noise component according to the present invention comprises: a first arrangement step for arranging a magnetic core 20 on a first lower mold 61 so that a corner portion of a boundary 213 of the magnetic core 20 is supported by the first lower mold 61, and receiving the magnetic core 20 in a receiving part 631 of a middle mold 63 while placing the middle mold 63 on the first lower mold 61; a first molding step for filling a first space 67 formed by a first upper mold 65, the middle mold 63, and the first lower mold 61 with a first resin 40 while arranging the first upper mold 65 on the middle mode 63; a second arrangement step for sandwiching the middle mold 63 between a second upper mold 71 and a second lower mold 73 and forming a second space 75 by the second upper mold 73, the middle mold 63, and the second lower mold 71 in a state in which the magnetic core 20 is held by the first resin 40 in the receiving part 631 of the middle mold 63; and a second molding step for filling the second space 75 with a second resin 50.

Description

Noise countermeasure component

[0009] ,

[0008] , ,

[0007] , ,

[0006] , ,

[0001] The present invention relates to a noise countermeasure component.

[0002] Patent Document 1 discloses a noise countermeasure component that can be easily fixed to the leads of an electronic component and can prevent the component from falling off the leads after being fixed.

[0003] The noise countermeasure component disclosed in Patent Document 1 includes a magnetic body having a through hole and an elastomer part attached to the magnetic body. This noise countermeasure component has a structure in which the magnetic body is disposed inside the elastomer part.

[0004] The elastomer part has an introduction path through which the lead of the electronic component is introduced at a position penetrating the through hole of the magnetic body. The introduction path is provided with a tapered part that at least partially narrows the introduction path from one end to the other end.

[0005] When the lead of the electronic component is introduced into the introduction path of the elastomer part, the elastomer part elastically deforms and presses against the lead. As a result, the magnetic body is suppressed from slipping down due to its own weight along the lead.

[0006] To form the elastomer part, a mold having a tapered surface is used. The magnetic body is supported in the mold by bringing the boundary between the end face and the inner peripheral surface of the magnetic body into contact with the tapered surface of the mold. By molding the raw material composition of the elastomer part in that state, a noise countermeasure component in which the magnetic body is disposed inside the elastomer part can be obtained.

[0007] Japanese Patent No. 5555866

[0008] As described above, in the noise countermeasure component described in Patent Document 1, the molding of the elastomer part is performed in a state where the boundary between the end face and the inner peripheral surface of the magnetic body is brought into contact with the tapered part of the elastomer part. Therefore, in this noise countermeasure component, the boundary between the end face and the inner peripheral surface of the magnetic body is likely to be exposed from the elastomer part, and at this boundary part, there is a problem that the elastomer part is likely to peel off from the magnetic body.

[0009] Examples of magnetic materials used in noise suppression components include ferrite (MnZn / NiZn) cores and nanocrystal thin-band wound cores. While these cores exhibit good properties as noise suppression components, they are conductive. When conductive magnetic materials (magnetic cores) are used in noise suppression components, the elastomer portion may peel off, and if the magnetic material breaks and scatters into the surrounding area, it may cause a short circuit in the surrounding circuitry. Furthermore, if the elastomer portion peels off, the grip force on the lead decreases, and the mounting position of the noise suppression component on the lead may change during use. Therefore, it is desirable that the magnetic material in noise suppression components is not exposed to the outside and that the elastomer portion is resistant to peeling.

[0010] One possible method for completely covering the magnetic material (magnetic core) with an elastomer portion is to perform the molding of the elastomer portion in two stages: primary molding and secondary molding. However, performing the molding process twice is cumbersome. When considering mass production of noise suppression components, it is desirable to eliminate or reduce the complexity of the manufacturing process.

[0011] Therefore, the present invention aims to provide a method for manufacturing noise suppression components that employs a molding process in which secondary molding is performed to completely cover the magnetic core with resin, while also eliminating or reducing complexity as much as possible, taking mass production into consideration.

[0012] Furthermore, the present invention aims to provide a noise suppression component in which the magnetic core is completely covered with resin and the resin is difficult to peel off from the magnetic core.

[0013] One aspect of the present invention provides a method for manufacturing a first noise suppression component, comprising: a first arrangement step of arranging the magnetic core on a first lower mold such that the corner of the boundary between the lower end of the magnetic core and the inner circumferential surface is supported by the first lower mold, and placing a plate-shaped medium mold having a receiving portion on the first lower mold, and receiving the magnetic core in the receiving portion of the medium mold; a first molding step of arranging a first upper mold on the medium mold and filling a first resin into a first space formed by the first upper mold, the medium mold and the first lower mold; a second arrangement step of sandwiching the medium mold between a second upper mold and a second lower mold, which are different from the first upper mold and the first lower mold, while the magnetic core is held in the first resin within the receiving portion of the medium mold, and forming a second space with the second upper mold, the medium mold and the second lower mold; and a second molding step of filling a second resin into the second space.

[0014] Another aspect of the present invention provides a noise suppression component, as a first noise suppression component, comprising a magnetic core and an outer resin, wherein the magnetic core has a through hole and an upper end surface, a lower end surface, an inner circumferential surface and an outer circumferential surface, the outer resin completely encloses the magnetic core, and an upper parting line and a lower parting line are formed on the outer circumference of the outer resin, separated from each other in the vertical direction.

[0015] In a method for manufacturing noise suppression components according to one aspect of the present invention, the mold used in the first molding step is also used in the second molding step. The primary molded product is held within the receiving portion of the mold and can be handled integrally with the mold. When manufacturing multiple noise suppression components simultaneously using a set of molds, multiple primary molded products can be handled integrally with a single mold, thereby eliminating or reducing complexity in a molding process that involves two molding steps.

[0016] By referring to the attached drawings and considering the following description of the best embodiment, the object of the present invention will be correctly understood, and its configuration will be more fully understood.

[0017] Figure 1 is a top perspective view showing a noise suppression component according to the first embodiment of the present invention. The boundary between the first resin and the second resin is shown by a dashed line. Figure 1 is a bottom perspective view showing the noise suppression component of Figure 1. The boundary between the first resin and the second resin is shown by a dashed line. Figure 1 is a bottom view showing the noise suppression component of Figure 1. The boundary between the first resin and the second resin is shown by a dashed line. Figure 3 is a cross-sectional view taken along line A-A showing the noise suppression component of Figure 3. Figure 3 is a cross-sectional view taken along line B-B showing the noise suppression component of Figure 3. (a) and (b) are schematic diagrams showing cross-sections perpendicular to the extension direction of the lead. Figure 1 is a diagram showing one step in the method for manufacturing the noise suppression component of Figure 1. Figure 7 is a diagram showing one step after the step shown in Figure 7. Figure 8 is a diagram showing one step after the step shown in Figure 8. Figure 9 is a diagram showing one step after the step shown in Figure 9. Figure 10 is a diagram showing one step after the step shown in Figure 11. Figure 12 is a diagram showing one step after the step shown in Figure 12. Figure 13 is a diagram showing one step after the step shown in Figure 13. Figure 14 is a diagram showing one step after the step shown in Figure 14. Figure 15 is a diagram showing one step after the step shown in Figure 15. Figure 16 is a diagram showing one step after the step shown in Figure 16. This figure shows one step after the process shown in Figure 17. This figure shows one step after the process shown in Figure 18. This is a cross-sectional view showing a noise suppression component according to a second embodiment of the present invention. This figure shows one step in the method for manufacturing the noise suppression component shown in Figure 20. This figure shows one step after the process shown in Figure 21.

[0018] While the present invention can be realized in various forms and variations, a specific embodiment shown in the drawings will be described in detail below as one example. The drawings and embodiments are not limited to the specific embodiments disclosed herein, but include all modifications, equivalents, and alternatives made within the scope expressly set forth in the appended claims.

[0019] (First Embodiment) Referring to Figures 1 to 3, the noise suppression component 10 according to one embodiment of the present invention has a substantially cylindrical outer shape and has an outer casing hole 12 that penetrates its center in the vertical direction. The noise suppression component 10 according to this embodiment is attached to the lead (not shown) of a predetermined component using the outer casing hole 12 when in use. In this embodiment, the vertical direction is the Z direction. The +Z direction is upward, and the -Z direction is downward.

[0020] Referring to Figures 4 and 5, the noise suppression component 10 comprises a magnetic core 20 and an outer resin 30. In this embodiment, the outer resin 30 has a first resin 40 and a second resin 50. As will be described later, the first resin 40 is molded by primary molding (first molding step), and the second resin 50 is molded by secondary molding (second molding step) which is performed after primary molding. Thus, in this embodiment, the outer resin 30 has a first resin 40 molded during primary molding and a second resin 50 molded during secondary molding.

[0021] As can be seen from Figures 3 to 5, the magnetic core 20 has a cylindrical shape. More specifically, the magnetic core 20 has a through hole 22 along a central axis extending in the vertical direction, and also has an upper end surface 201, a lower end surface 203, an inner circumferential surface 205, and an outer circumferential surface 207.

[0022] As shown in Figures 4 and 5, the magnetic core 20 has a first boundary 211 as the boundary between the lower end surface 203 and the outer circumferential surface 207. The magnetic core 20 also has a second boundary 213 as the boundary between the lower end surface 203 and the inner circumferential surface 205. Furthermore, the magnetic core 20 has a third boundary 215 as the boundary between the upper end surface 201 and the outer circumferential surface 207, and a fourth boundary 217 as the boundary between the upper end surface 201 and the inner circumferential surface 205.

[0023] As shown in Figures 4 and 5, the outer resin 30 completely encloses the magnetic core 20. More specifically, the first resin 40 covers the magnetic core 20 from the outer circumference, and the second resin 50 covers the magnetic core 20 from the inner circumference. In particular, the first boundary 211 and the third boundary 215 of the magnetic core 20 are covered by the first resin 40, and the second boundary 213 and the fourth boundary 217 of the magnetic core 20 are covered by the second resin 50. Since the magnetic core 20 is completely enclosed in the outer resin 30, even if the magnetic core 20 is damaged, fragments of the magnetic core 20 will not scatter outside the noise suppression component 10.

[0024] As shown in Figures 4 and 5, in this embodiment, the boundary between the first resin 40 and the second resin 50 is located above the upper end surface 201 and below the lower end surface 203 of the magnetic core 20, respectively. Since the boundary between the first resin 40 and the second resin 50 is far from areas where external forces are likely to act directly, the first resin 40 and the second resin 50 are unlikely to peel off from each other, and are also unlikely to peel off from the magnetic core 20. Areas where external forces are likely to act directly on the outer resin 30 are around the upper end 121 of the outer hole 12 and around the upper and lower ends of the outer circumference, respectively. However, the present invention is not limited thereto. The boundary between the first resin 40 and the second resin 50 can be set arbitrarily.

[0025] As shown in Figures 4 and 5, in this embodiment, the outer casing hole 12 is formed of the second resin 50. The outer casing hole 12 corresponds to the through hole 22 of the magnetic core 20. In other words, the outer casing hole 12 passes inside the through hole 22 of the magnetic core 20. The second resin 50 is elastically deformable and can at least partially enlarge the diameter of the outer casing hole 12.

[0026] As can be seen from Figures 1 and 3, in this embodiment, when viewed along the vertical direction, the shape of the upper end 121 of the outer casing hole 12 is circular. This corresponds to a cross-sectional shape perpendicular to the extending direction of the lead (not shown) of a predetermined component. Also, as can be seen from Figures 2 and 3, in this embodiment, when viewed along the vertical direction, the shape of the lower end 123 of the outer casing hole 12 is racetrack-shaped. However, the present invention is not limited thereto. The shape of the upper end 121 of the outer casing hole 12 does not have to be circular, as long as it corresponds to the cross-sectional shape of the lead. Also, the shape of the lower end 123 of the outer casing hole 12 may be circular, elliptical, polygonal, etc., when viewed along the vertical direction.

[0027] As can be seen from Figures 3 to 5, in this embodiment, the cross-sectional area of ​​the upper end 121 of the outer casing hole 12 is smaller than the cross-sectional area of ​​the lower end 123 of the outer casing hole 12. In other words, in this embodiment, the cross-sectional area of ​​the outer casing hole 12 perpendicular to the vertical direction generally decreases from bottom to top. This is to allow for smooth insertion and press-fitting of a lead (not shown) into the outer casing hole 12 during use. To achieve this configuration, the outer casing hole 12 is provided with a tapered portion 125 whose diameter decreases from bottom to top. In this embodiment, the outer casing hole 12 is provided with a plurality of tapered portions 125 (125-1, 125-2, 125-3) with different inclinations. As can be seen from Figures 2 to 5, in a cross-section perpendicular to the vertical direction, the shape of tapered portion 125-1 is circular. Also, in a cross-section perpendicular to the vertical direction, the shape of the upper end of tapered portion 125-2 is circular, and the shape of the lower end is racetrack-shaped. In other words, the cross-sectional shape of the tapered portion 125-2 changes from circular to racetrack-shaped as it moves from the upper end to the lower end. Furthermore, in a cross-section perpendicular to the vertical direction, the shape of the tapered portion 125-3 is racetrack-shaped. The shapes of these tapered portions 125 are designed to accommodate both round-shaped and rectangular-shaped terminals when the terminal connected to the end of the lead is at least partially received in the outer casing hole 12. However, the present invention is not limited thereto. The outer casing hole 12 only needs to have at least one tapered portion 125. Also, in a cross-section perpendicular to the vertical direction, the shapes of all the tapered portions 125 may be similar to each other, for example, circular, rectangular, or racetrack-shaped. Furthermore, in this embodiment, each of the tapered portions 125 is represented by a straight line in a cross-section along the vertical direction, but it may also be represented by a curve.

[0028] The cross-sectional area of ​​the upper end 121 of the outer casing hole 12 is smaller than the cross-sectional area of ​​the lead (not shown) of a predetermined component. In other words, the minimum diameter Dmin of the outer casing hole 12 (see Figure 3) is smaller than the maximum size Slmax (see Figure 6) on the cross section perpendicular to the extension direction of the lead of the predetermined component. In this embodiment, the minimum diameter Dmin of the outer casing hole 12 is the diameter of the upper end 121 of the outer casing hole 12, as shown in Figure 3. The maximum size Slmax of the lead is the diameter of the cross section perpendicular to the extension direction or length direction of the lead if it is circular, as shown in Figure 6, and the major axis if it is elliptical or racetrack shaped. As a result, when the lead is pressed into the outer casing hole 12 during use, the second resin 50 elastically deforms so that the outer casing hole 12 is partially expanded, and the second resin 50 holds the lead by its restoring force. As a result, the noise suppression component 10 is fixed in position relative to the lead, preventing movement relative to the lead or detachment from the lead.

[0029] The noise suppression component 10 is manufactured, for example, as follows. Although the following description explains the manufacturing of one noise suppression component 10, by using a mold that supports the simultaneous manufacturing of multiple noise suppression components 10, it is possible to manufacture multiple noise suppression components 10 simultaneously through the following process. The mold includes a first lower mold 61 (61A), a middle mold 63, a first upper mold 65 (65A), a second lower mold 71 (71A), and a second upper mold 73 (73A).

[0030] First, as shown in Figure 7, a magnetic core 20 is prepared and placed on the first lower mold 61 (first step). This first step is performed so that the first lower mold 61 supports the corner of the boundary between the lower end surface 203 and the inner circumferential surface 205 of the magnetic core 20, i.e., the second boundary 213. In other words, this arrangement is performed so that the first lower mold 61 supports the corner of the magnetic core 20 including the second boundary 213. In this embodiment, the first lower mold 61 partially supports the lower end surface 203 of the core from below in the vertical direction. The first lower mold 61 also supports the inner circumferential surface 205 of the magnetic core 20 in a direction perpendicular to the vertical direction. By supporting the corner of the magnetic core 20 with the first lower mold 61 in this way, the magnetic core 20 can be stably positioned on the first lower mold 61. Conventionally, the magnetic core was supported by an annular line, which meant there was a risk of the magnetic core tilting relative to the lower mold. However, in this embodiment, the magnetic core 20 is supported by a surface, so there is no risk of the magnetic core 20 tilting relative to the first lower mold 61.

[0031] Next, as shown in Figure 8, the medium mold 63 is placed on the first lower mold 61 (second step). The medium mold 63 is plate-shaped and has a predetermined thickness. The medium mold 63 also has a receiving portion 631 that is sized to receive the magnetic core 20. The receiving portion 631 is open at the top and bottom, respectively. In this embodiment, the medium mold 63 has a protruding portion 633 that projects into the receiving portion 631. The protruding portion 633 rises gently inward from the receiving portion 631. By placing the medium mold 63 on the first lower mold 61, the magnetic core 20 is received in the receiving portion 631. Note that this second step may be performed simultaneously with the first step. Alternatively, this second step may be performed before the first step. In any case, the first step and the second step constitute the first placement step.

[0032] Next, a first resin material 42 is prepared as shown in Figure 9 (third step). Subsequently, a first upper mold 65 is prepared as shown in Figure 10, and the first upper mold 65 is placed on the middle mold 63 as shown in Figure 11 (fourth step). In the fourth step, a first space 67 is formed by the first upper mold 65, the middle mold 63, and the first lower mold 61. By softening the first resin material 42 while forming the first space 67, the first resin material 42 is filled into the first space 67, and the first resin 40 is formed. Thus, the first molding step is performed in which the first upper mold 65 is placed on the middle mold 63, and the first resin 40 is filled into the first space 67 formed by the first upper mold 65, the middle mold 63, and the first lower mold 61. In the molding of the first resin 40 using the medium mold 63, two parting lines (not shown), namely an upper parting line and a lower parting line, are formed at the mold boundary on the outer surface of the first resin 40. The upper parting line and the lower parting line are located apart from each other in the vertical direction. The vertical distance between the upper parting line and the lower parting line corresponds to the thickness of the medium mold 63. In other words, the presence of these parting lines indicates that the noise suppression component 10 was manufactured using the medium mold 63.

[0033] Next, as shown in Figure 12, the first upper mold 65 is removed from the middle mold 63 (fifth step), and then, as shown in Figure 13, the first lower mold 61 is removed from the middle mold 63 (sixth step). Steps 5 and 6 may be performed simultaneously.

[0034] As shown in Figure 13, the primary molded product remains inside the receiving portion 631 of the medium mold 63. In other words, the magnetic core 20 remains inside the receiving portion 631, held in place by the first resin 40. The protrusions 633 of the medium mold 63 help to hold the primary molded product inside the receiving portion 631.

[0035] Next, as shown in Figure 14, the medium mold 63 is placed on the second lower mold 71 together with the magnetic core 20 and the first resin 40 (seventh step). The second lower mold 71 is a different mold from the first lower mold 61. By using the medium mold 63, the primary molded product can be aligned with the second lower mold 71 with high accuracy and ease.

[0036] Next, as shown in Figure 15, the second upper mold 73 is placed on the medium mold 63 (step 8). The second upper mold 73 is a different mold from the first upper mold 65.

[0037] In the seventh and eighth steps described above, the medium mold 63 is sandwiched between the second upper mold 73 and the second lower mold 71 while the magnetic core 20 is held in the first resin 40 within the receiving portion 631 of the medium mold 63. The seventh and eighth steps constitute the second arrangement step, thereby forming a second space 75 between the second upper mold 73, the medium mold 63, and the second lower mold 71. In this embodiment, the second resin material 52 is set in the second upper mold 73.

[0038] Next, as can be seen from Figures 16 and 17, the second resin material 52 is melted and the second resin 50 is filled into the second space 75 using the plunger 77 (9th step). This 9th step constitutes the second molding step.

[0039] Next, as shown in Figure 18, the second upper mold 73 is removed from the middle mold 63, and then the second lower mold 71 is removed from the middle mold 63 (10th step). As a result, a secondary molded product, i.e., the noise suppression component 10, held in the middle mold 63, is obtained, as shown in Figure 19. Finally, the secondary molded product is removed from the middle mold 63 (11th step). The first resin 40 is elastically deformable and can be removed from the middle mold 63 regardless of the presence of the protrusions 633. In this way, the noise suppression component 10 shown in Figures 1 and 2 can be obtained.

[0040] As described above, in the manufacturing of the noise suppression component 10 according to this embodiment, the intermediate mold 63 is used in common in the first molding step and the second molding step. Since the primary molded product can be held in the intermediate mold 63 and the process can proceed to the secondary molding step, there is no need to remove the primary molded product from the intermediate mold 63 and set it in the secondary mold (second lower mold 71 and second upper mold 73). In addition, aligning the intermediate mold 63 with the secondary mold is easier than when setting the primary molded product in the secondary mold. Therefore, the handling of the primary molded product is easy, and the manufacturing process does not become complicated even if molding is performed twice. In particular, when manufacturing multiple noise suppression components 10 simultaneously, multiple primary molded products can be handled together, so high manufacturing efficiency can be expected. In addition, by using the intermediate mold 63, the outer resin 30 or the second resin 50 can be given sufficient thickness around the corner of the second boundary 213 that was supported by the first lower mold 61, making it difficult for the outer resin 30 to peel off.

[0041] (Second Embodiment) Referring to Figure 20, the noise suppression component 10A according to the second embodiment comprises a magnetic core 20 and an outer resin 30A. The outer resin 30A has a first resin 40A and a second resin 50A. The basic configuration of the noise suppression component 10A is the same as the basic configuration of the noise suppression component 10 of the first embodiment. The difference between the noise suppression component 10A and the noise suppression component 10 lies in the shape of the first resin 40A and the second resin 50A.

[0042] As shown in Figure 20, in this embodiment, both the upper end surface 401 and the lower end surface 403 of the first resin 40A are covered by the second resin 50A. In this embodiment, the boundary between the first resin 40A and the second resin 50A that is exposed to the outside is located on the outer periphery of the outer resin 30A. The contact area between the second resin 50A and the first resin 40A is wider than that of the noise suppression component 10 according to the first embodiment. With this configuration, the second resin 50A is less likely to peel off from the first resin 40A.

[0043] The manufacturing of the noise countermeasure component 10A can be performed in the same process as the manufacturing of the noise countermeasure component 10 of the first embodiment. However, the mold used for manufacturing the noise countermeasure component 10A has a different shape from the mold used for manufacturing the noise countermeasure component 10, except for the medium-sized 63.

[0044] Referring to FIG. 21, the first molding step in the present embodiment is performed using the first lower mold 61A, the medium-sized mold 63, and the first upper mold 65A. In the present embodiment, the position of the upper end surface 401 of the first resin 40A is lower in the vertical direction than the position of the upper surface 641 of the medium-sized mold 63. Also, the position of the lower end surface 403 of the first resin 40A is higher in the vertical direction than the position of the lower surface 643 of the medium-sized mold 63. This is to make the position of the burr that may occur in the first molding step different from the position of the burr that may occur in the second molding step. However, the present invention is not limited to this. The position of the upper end surface 401 of the first resin 40A may be the same as the position of the upper surface 641 of the medium-sized mold 63 in the vertical direction. Also, the position of the lower end surface 403 of the first resin 40A may be the same as the position of the lower surface 643 of the medium-sized mold 63 in the vertical direction.

[0045] Referring to FIG. 22, the second molding step in the present embodiment is performed using the second lower mold 71A, the second upper mold 73A, and the medium-sized mold 63 that holds the primary molded product. The parting line surface, which is the boundary between the second lower mold 71A and the medium-sized mold 63, is located below the lower end surface 403 of the first resin 40A in the vertical direction. Also, the parting line surface, which is the boundary between the second upper mold 73A and the medium-sized mold 63, is located above the upper end surface 401 of the first resin 40A in the vertical direction. The parting line formed by the second molding step is formed on the outer periphery of the second resin 50A. Specifically, an upper parting line and a lower parting line, which are separated from each other in the vertical direction, are formed on the outer periphery of the second resin 50A. The presence of these parting lines indicates that the manufacturing of the noise countermeasure component 10A was performed using the medium-sized mold 63.

[0046] As described above, the manufacturing method of the noise countermeasure components 10 and 10A according to the present embodiment involves performing the molding process twice. However, by using the medium-sized 63, the complexity of these processes is eliminated or reduced, so that the manufacturing of the noise countermeasure component 10 or 10A can be easily carried out. Moreover, this method is suitable for mass production. In addition, in the noise countermeasure component 10 or 10A manufactured by this method, the exterior resin 30 or 30A completely encapsulates the magnetic core 20 and is difficult to peel off. Therefore, even if the magnetic core 20 is damaged, it will not scatter around. Also, the noise countermeasure components 10 and 10A can have sufficient holding force for the leads.

[0047] As described above, the present invention has been described with reference to several embodiments. However, the present invention is not limited to the above embodiments, and various modifications and changes are possible without departing from the gist of the present invention. For example, in the above embodiment, the first molding step is performed by the compression method and the second molding step is performed by the injection method, respectively. However, the present invention is not limited to this. The first molding step may be performed by the transfer method, or the second molding step may be performed by the compression method. Also, the first molding step and the second molding step may be performed by the same method.

[0048] The present invention is based on Japanese Patent Application No. 2025-006946 filed with the Japan Patent Office on January 17, 2025, the content of which is incorporated herein by reference and forms a part of this specification.

[0049] Although the best mode for carrying out the present invention has been described, as will be apparent to those skilled in the art, it is possible to modify the embodiments without departing from the spirit of the present invention, and such embodiments belong to the scope of the present invention.

[0050] 10, 10A Noise suppression component 12 Outer hole 121 Upper end 123 Lower end 125 Tapered section 20 Magnetic core 201 Upper end surface 203 Lower end surface 205 Inner circumferential surface 207 Outer circumferential surface 211 First boundary 213 Second boundary 215 Third boundary 217 Fourth boundary 22 Through hole 30, 30A Outer resin 40, 40A First resin 401 Upper end surface 403 Lower end surface 42 First resin material 50, 50A Second resin 52 Second resin material 61, 61A First lower mold 63 Middle mold 631 Receiving part 633 Protruding part 641 Upper surface 643 Lower surface 65, 65A First upper mold 67 First space 71, 71A Second lower mold 73, 73A Second upper type 75 Second space 77 Plunger

Claims

1. A method for manufacturing a noise suppression component, comprising:

1. A first arrangement step of arranging the magnetic core on a first lower mold such that the corner of the boundary between the lower end surface and the inner circumferential surface of the magnetic core is supported by the first lower mold, and a plate-shaped medium mold having a receiving portion is placed on the first lower mold, and the magnetic core is received in the receiving portion of the medium mold; 2. A first molding step of arranging a first upper mold on the medium mold and filling a first resin into a first space formed by the first upper mold, the medium mold and the first lower mold; 3. A second arrangement step of sandwiching the medium mold between a second upper mold and a second lower mold, which are different from the first upper mold and the first lower mold, while the magnetic core is held in the first resin within the receiving portion of the medium mold, and forming a second space with the second upper mold, the medium mold and the second lower mold; and 4. A second molding step of filling a second resin into the second space.

2. A noise suppression component comprising a magnetic core and an outer resin, wherein the magnetic core has a through hole and an upper end surface, a lower end surface, an inner circumferential surface and an outer circumferential surface, the outer resin completely encloses the magnetic core, and an upper parting line and a lower parting line are formed on the outer circumference of the outer resin, which are spaced apart from each other in the vertical direction.

3. A noise suppression component according to claim 2, wherein the noise suppression component is attached to the lead of a predetermined component when in use, the outer resin has an outer hole corresponding to the through hole of the magnetic core, and the minimum diameter of the outer hole is smaller than the longest size on a cross section perpendicular to the extending direction of the lead of the predetermined component.

4. A noise suppression component according to claim 3, wherein the outer casing hole of the outer casing resin has a tapered portion formed therein, the diameter of which decreases from bottom to top.

5. A noise suppression component according to any one of claims 2 to 4, wherein the magnetic core has a first boundary as the boundary between the lower end surface and the outer circumferential surface, and a second boundary as the boundary between the lower end surface and the inner circumferential surface, the outer resin comprises a first resin molded during primary molding and a second resin molded during secondary molding, the first boundary of the magnetic core is covered by the first resin, and the second boundary of the magnetic core is covered by the second resin.

6. A noise suppression component according to claim 5, wherein both the upper and lower end surfaces of the first resin are covered with the second resin, and the boundary between the first resin and the second resin is located on the outer periphery of the outer resin.

7. A noise suppression component according to claim 6, wherein the upper parting line and the lower parting line are located on the second resin.

8. A noise suppression component according to any one of claims 5 to 7, wherein the boundary between the first resin and the second resin is located above the upper end surface and below the lower end surface of the magnetic core, respectively.

Images